Oscillating Heat Pipe Assembly for Electrical Machine Thermal Management
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Solution Overview
Problem
Electrical machines face performance degradation, reduced power density, and reliability issues due to high temperatures, particularly in components like stator slots where ohmic losses generate heat, which is poorly dissipated through insulation layers with low thermal conductivity.
Innovation Solution
Incorporation of an oscillating heat pipe assembly made of dielectric material with higher in-plane thermal conductivity than through-plane conductivity, placed in contact with magnetic field-generating components and cores, to effectively dissipate heat from hot spots within electrical machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation layers are used to protect components from short circuit, then electrical reliability is improved, but thermal conductivity deteriorates causing poor heat extraction
Solution Approach 1:
A thermal interface material is introduced as an intermediary layer between the insulation layer and the heat-generating component. This intermediary material has high thermal conductivity to facilitate heat extraction while the insulation layer maintains its electrical insulation function, thus resolving the contradiction between electrical reliability and thermal management.
Solution Approach 2:
The patent employs composite material structures where thermally conductive materials are integrated with or adjacent to electrical insulation layers. This composite approach allows simultaneous achievement of electrical isolation and efficient heat transfer, addressing both the reliability requirement and the thermal management challenge.
2Temperature
If high thermal conductivity materials are used throughout the assembly, then heat extraction is improved, but electrical insulation performance deteriorates
Solution Approach 1:
Different regions of the assembly are assigned different material properties: thermally conductive materials are placed in heat extraction paths, while electrically insulating materials are positioned where electrical isolation is critical. This localized differentiation allows optimization of both thermal and electrical performance without compromise.
Solution Approach 2:
The assembly is segmented into distinct functional zones: one dedicated to thermal management with high thermal conductivity materials, and another dedicated to electrical insulation with appropriate insulating materials. This segmentation allows each zone to perform its primary function effectively without interfering with the other.
3Reliability
If more insulation layers are added to protect components, then electrical protection is improved, but thermal resistance increases reducing power density
Solution Approach 1:
A thermally conductive intermediary layer is inserted between the insulation layers and the heat-generating component. This intermediary acts as a thermal bridge that maintains electrical insulation while providing a low-resistance path for heat extraction, thereby preserving power density despite the presence of multiple insulation layers.
Solution Approach 2:
The patent uses composite material structures where thermally conductive fillers or additives are incorporated into insulation layers, or where alternating layers of insulating and thermally conductive materials are used. This composite approach maintains electrical protection while improving thermal management to sustain high power density.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances thermal management by efficiently conducting heat away from critical components, improving the reliability and power density of electrical machines by effectively managing temperature hotspots.
Implementation Method 1
the oscillating heat pipe assembly has an in-plane thermal conductivity higher than a through-plane thermal conductivity
Implementation Method 2
oscillating heat pipe assembly
Implementation Method 3
oscillating heat pipe assembly
Data Source
AI summary
A component for an electrical machine is disclosed. The component is a stator and/or a rotor. The component includes a core, a magnetic field-generating component, and an oscillating heat pipe assembly. The core includes a plurality of slots and the magnetic field-generating component is disposed in at least one slot of the plurality of slots. The oscillating heat pipe assembly is disposed in the core and the at least one slot of the plurality of slots. The oscillating heat pipe assembly is in contact with the core and the magnetic field-generating component. The oscillating heat pipe assembly includes a dielectric material, and where the oscillating heat pipe assembly has an in-plane thermal conductivity higher than a through-plane thermal conductivity.